Mobile Matrix Carrier Routing to Reduce Sortation Divert Complexity
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Solution Overview
Problem
Current object processing systems, such as sortation and automated storage and retrieval systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and high mechanical complexity, which increases costs and limits throughput and the number of divert locations.
Innovation Solution
The system employs a network of track sections with remotely actuatable carriers that can move along these sections in limited ranges, allowing for flexible and efficient movement of objects between different locations without requiring extensive bin duplication or complex divert mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation extent is improved, but device complexity increases due to actuators required for each divert
Solution Approach 1:
The patent replaces traditional mechanical tilt-tray actuators with a robotic system comprising mobile robots equipped with sensors and navigation capabilities. These robots autonomously transport objects from induction stations to collection bins, eliminating the need for complex mechanical actuators at each divert location while maintaining high automation levels
Solution Approach 2:
The patent introduces mobile robots as intermediary carriers between the induction station and collection bins. These robots serve as flexible mediators that can dynamically route objects to any destination without requiring fixed mechanical divert infrastructure, thereby reducing overall system complexity
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse object types, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The patent implements dynamic routing where mobile robots can be reassigned to different collection bins based on real-time sortation needs. This dynamic allocation allows the system to handle a large number of object types and destinations without requiring all bins to be simultaneously accessible, thereby reducing the physical space needed compared to static sortation systems
Solution Approach 2:
The patent divides the sortation system into modular components: induction stations, mobile robot carriers, and collection bins. This segmentation allows flexible positioning of bins in remote locations and enables the system to scale adaptability without proportionally increasing the area occupied by divert mechanisms
3Device complexity
If human workers perform manual sortation, then device complexity is reduced, but productivity is limited by human sorting speed
Solution Approach 1:
The patent implements self-service through autonomous mobile robots that independently navigate, identify objects via onboard sensors, determine optimal destinations, and transport items to collection bins without human intervention. This automation maintains relative system simplicity while dramatically increasing throughput beyond human capabilities
Solution Approach 2:
The patent replaces manual human sortation with an automated robotic system that uses sensors, processors, and mobile platforms. This substitution eliminates human speed limitations while avoiding the complexity of fully automated conveyor-based mechanical sortation systems
Data Source
AI summary
An object processing system is disclosed that includes a plurality of track sections, and a plurality of remotely actuatable carriers for controlled movement along at least portions of the plurality of track sections, each of the actuatable carriers being instructed at any time to move a limited number of track section only.